Extended reach crowd control for a shovel

ABSTRACT

An industrial machine and a method of controlling an industrial machine, the industrial machine including a dipper supported by a dipper handle. The method may include determining an operating phase of the industrial machine, in a first operating phase of the industrial machine, limiting, with at least one controller, a reach of the dipper handle, and in a second operating phase of the industrial machine, enabling, with the at least one controller, an extended reach of the dipper handle greater than the reach in the first operating phase. The industrial machine may include at least one controller configured to determine an operating phase of the industrial machine, in a first operating phase of the industrial machine, limit a reach of the dipper handle, and, in a second operating phase of the industrial machine, enable an extended reach of the dipper handle greater than the reach in the first operating phase.

RELATED APPLICATION

The present application is a continuation of prior-filed, co-pendingU.S. application Ser. No. 13/842,634, filed Mar. 15, 2013, which claimsthe benefit of and priority to U.S. Provisional Patent Application No.61/686,313, filed Apr. 3, 2012. The entire contents of both of theseapplications are hereby incorporated by reference.

FIELD

This invention generally relates to an industrial machine, such as anelectric rope or power shovel, and, more particularly, to an extendedreach and a control for the extended reach for an industrial machine.

SUMMARY

Industrial machines, such as electric rope or power shovels, draglines,etc., are used to execute digging operations to remove material from,for example, a bank of a mine. An operator controls a rope shovel duringa dig operation or phase to load a dipper with materials. The operatordeposits the materials in the dipper into a hopper or a truck during atruck loading or truck spotting phase. After unloading the materials,the dig cycle continues, and the operator swings the dipper back to thebank to perform additional digging during a return to tuck phase.

The dipper is connected to a pivotable handle, which is attached to aboom. Multiple hoist cables and motors are used to raise and lower thedipper and extend and retract (i.e., crowd extension or retraction) thedipper. The length of the handle supporting the dipper defines the reachof the dipper, and, in existing shovels, the entire length of the handlecan be used to perform each phase of the dig cycle. However, for somephases, additional reach of the dipper may be advantageous and may leadto an improved dig cycle. To provide this extended reach, the length ofthe handle can be extended. However, the length of the handle may belimited based on the position of hoist cables or other components of theshovel. Furthermore, for some phases of the dig cycle, extended reach ofthe dipper may be unnecessary, inefficient, etc. and/or create excessiveloading in the structure of the machine.

Therefore, independent embodiments of the invention may allow foroptimal dipper extension during the digging phase while extendingavailable dipper reach during the truck loading or spotting phase to,for example, aid the shovel operator in properly filling the truck. Forexample, one independent embodiment extends the available reach of thedipper during the truck loading phase. In some embodiments, thisextended reach is accomplished without extending the effective length ofthe handle, which often results in interference with other components ofthe shovel. Some embodiments use a modified handle design and geometrythat includes an unsymmetrical chamfer on the handle end in place of asymmetrical rounded end.

In one independent aspect, a method of controlling an industrial machinemay be provided. The industrial machine including a dipper supported bya dipper handle. The method may generally include determining anoperating phase of the industrial machine, in a first operating phase ofthe industrial machine, limiting, with at least one controller, a reachof the dipper handle, and in a second operating phase of the industrialmachine, enabling, with the at least one controller, an extended reachof the dipper handle greater than the reach in the first operatingphase.

In another independent aspect, an industrial machine, such as a shovel,may generally include a dipper handle, a dipper supported by the dipperhandle, and at least one controller configured to determine an operatingphase of the industrial machine, in a first operating phase of theindustrial machine, limit a reach of the dipper handle, and in a secondoperating phase of the industrial machine, enable an extended reach ofthe dipper handle greater than the reach in the first operating phase.

In yet another independent aspect, an assembly for an industrialmachine, such as a shovel, may be provided. The assembly may generallyinclude a dipper handle operable to support a dipper, the dipper handlehaving an end surface defining a first mounting position and a secondmounting position, and a bracket having a first surface engageableagainst the end surface and an opposite, second surface, a first liftingopening being provided on the second surface, the bracket having a firstend defining a guide surface and an opposite, second end, a secondlifting opening being provided on the second end, the bracket beingselectively connectable to the end surface of the dipper handle in thefirst mounting position in a first orientation relative to the dipperhandle and in the second mounting position in a second orientationrelative to the dipper handle.

Other independent aspects of the invention will become apparent byconsideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a shovel according to an independent embodiment ofthe invention during a loading phase.

FIG. 1B is a view of an alternative construction of a shovel during atruck loading phase.

FIG. 2 illustrates a controller for the shovel of FIGS. 1A-1B.

FIG. 3 is a flow chart illustrating a control method executed by thecontroller of FIG. 2.

FIG. 4 graphically illustrates limiting bail pull.

FIG. 5A is a perspective view of a portion of a modified handle for theshovel of FIGS. 1A-1B and of a portion of an existing handle.

FIG. 5B is another perspective view of the portion of the modifiedhandle shown in FIG. 5A.

FIG. 5C is a side view of the existing handle shown in FIG. 5A.

FIGS. 6A-6C are views of a portion of the shovel of FIG. 1B.

FIG. 7A is a side view of a portion of another alternative constructionof a shovel and illustrating limited reach of a dipper handle during adigging phase.

FIG. 7B is an enlarged perspective view of a portion of the shovel shownin FIG. 7A.

FIG. 7C is an enlarged view of the portion of the shovel shown in FIG.7B with components removed to illustrate the limited reach of the dipperhandle during the digging phase.

FIG. 8A is a side view of the portion of the shovel shown in FIG. 7A andillustrating extended reach of the handle during a loading phase.

FIG. 8B is an enlarged view of a portion of the shovel shown in FIG. 8Awith components removed to illustrate the extended reach of the dipperhandle during the loading phase.

FIG. 8C is an enlarged view of the portion of the shovel shown in FIG.8B and illustrating the hard stop limit for the handle extension.

FIGS. 9A-9B are views of the handle of the shovel shown in FIGS. 7A and8A.

FIGS. 9C-9D are views of a portion of the handle shown in FIGS. 9A-9B.

FIGS. 10A-10D are views of a lifting bracket.

FIGS. 11A-11B are perspective views of the handle shown in FIGS. 9A-9Dincluding the lifting bracket shown in FIGS. 10A-10D and illustrating atransport removal position of the bracket.

FIG. 11C is a perspective view of the handle and brackets andillustrating a standing position of the brackets.

FIG. 11D is a perspective view of the handle and brackets andillustrating a standing handle assembly position of the brackets.

FIGS. 12A-12H are views illustrating assembly of the handle to the boomin the standing handle position.

FIGS. 13A-13D are views illustrating assembly of the handle to the boomin a lifted handle position.

FIGS. 14A-14B are perspective views of the handle and bracket andillustrating the bracket in a storage position.

DETAILED DESCRIPTION

Before any independent embodiments of the invention are explained indetail, it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangement ofcomponents set forth in the following description or illustrated in thefollowing drawings. The invention is capable of other independentembodiments and of being practiced or of being carried out in variousways.

Also, it is to be understood that the phraseology and terminology usedherein is for the purpose of description and should not be regarded aslimited. The use of “including,” “comprising” or “having” and variationsthereof herein is meant to encompass the items listed thereafter andequivalents thereof as well as additional items. The terms “mounted,”“connected” and “coupled” are used broadly and encompass both direct andindirect mounting, connecting and coupling. Further, “connected” and“coupled” are not restricted to physical or mechanical connections orcouplings, and can include electrical connections or couplings, whetherdirect or indirect. In addition, electronic communications andnotifications may be performed using any known means including directconnections, wireless connections, etc.

It should be noted that a plurality of hardware and software baseddevices, as well as a plurality of different structural components maybe utilized to implement aspects of the invention. Furthermore, and asdescribed in subsequent paragraphs, the specific configurationsillustrated in the drawings are intended to exemplify embodiments of theinvention and that other alternative configurations are possible.

FIG. 1A illustrates an industrial machine, such as, for example, a ropeshovel 100. The rope shovel 100 includes tracks 105 for propelling therope shovel 100 forward and backward, and for turning the rope shovel100 (i.e., by varying the speed and/or direction of the left and righttracks 105 relative to each other). The tracks 105 support a base 110including a cab 115. The base 110 is able to swing or swivel about aswing axis 125 to move from a digging location to a dumping location andback to a digging location. The rope shovel 100 further includes a boom130 that supports a pivotable dipper handle 135 and a dipper 140. Thedipper 140 includes a door 145 for dumping contents contained within thedipper 140. A door cable 160 operates the door 145.

The rope shovel 100 also includes taut suspension cables 150 coupledbetween the base 110 and boom 130 for supporting the boom 130 and ahoist cable 155 attached to a winch (not shown) within the base 110 forwinding the cable 155 to raise and lower the dipper 140. The dipperhandle 135 includes a rack tooth formation thereon which engages a drivepinion (not shown in FIG. 1A) mounted in a saddle block 157. The drivepinion is driven by an electric motor and transmission unit (not shown)to extend or retract the dipper handle 135 relative to the saddle block157. Wear plates 158 in the saddle block 157 engage the dipper handle135.

An electrical power source provides power to one or more hoist electricmotors for driving the winch drum, one or more crowd electric motors fordriving the saddle block transmission unit, and one or more swingelectric motors for turning the base 110. Each of the hoist, crowd andswing motors can be driven by its own motor controller or drive inresponse to control signals from a controller, as described below.

FIG. 1A also depicts a mobile mining crusher 175. During operation, therope shovel 100 dumps materials contained within the dipper 140 into ahopper 170 of the crusher 175 by opening the door 145 when the dipper140 is positioned over the hopper 170. As shown in FIG. 1B, a ropeshovel 100A is illustrated dumping material into a dump truck 175A.Although the rope shovels 100, 100A are described as being used with themobile mining crusher 175 or a dump truck 175A, the rope shovel 100,100A is also able to dump materials from the dipper 140 into othermaterial collectors or directly onto the ground.

The shovel 100 also includes a controller. The controller includescombinations of hardware and software that are operable to, among otherthings, control operation of the shovel 100. A controller 300 accordingto one independent embodiment of the invention is illustrated in FIG. 2.As illustrated in FIG. 2, the controller 300 includes a processing unit350 (e.g., a microprocessor, a microcontroller, or another suitableprogrammable device), non-transitory computer-readable media 355, and aninput/output interface 365. The processing unit 350, the media 355, andthe input/output interface 365 are connected by one or more controland/or data buses. The control and/or data buses are shown generally inFIG. 2 for illustrative purposes. It should be understood that in otherconstructions, the controller 300 includes additional, fewer, ordifferent components. It should be understood that the functionality ofthe controller 300 may be distributed among multiple control devices orcontrol systems.

The computer-readable media 355 stores program instructions and data.The processing unit 350 is configured to retrieve instructions from themedia 355 and execute the instructions to perform the control processesand methods described herein. The input/output interface 365 transmitsdata from the controller 300 to external systems, networks, and/ordevices and receives data from external systems, networks, and/ordevices. The input/output interface 365 stores data received fromexternal sources to the media 355 and/or provides the data to theprocessing unit 350.

As illustrated in FIG. 2, the controller 300 receives input from anoperator interface 370. The operator interface 370 includes a crowdcontrol, a swing control, a hoist control, and a door control. The crowdcontrol, swing control, hoist control, and door control includeoperator-controlled input devices such as joysticks, levers, footpedals, and other actuators.

The operator interface 370 receives operator input via the input devicesand outputs digital motion commands to the controller 300. The motioncommands can include hoist up, hoist down, crowd extend, crowd retract,swing clockwise, swing counterclockwise, dipper door release, left trackforward, left track reverse, right track forward, and right trackreverse. Upon receiving a motion command, the controller 300 generallycontrols one or more motors or mechanisms (e.g., a crowd motor, swingmotor, hoist motor, and/or a shovel door latch) as commanded by theoperator.

In some embodiments, the controller 300 can also provide feedback to theoperator through the operator interface 370. For example, if thecontroller 300 has enabled extended crowd reach (described below), thecontroller 300 may interact with the operator interface 370 to notifythe operator of this enablement (e.g., using visual, audible, or hapticfeedback).

The controller 300 is also in communication with a number of sensors 380to monitor the location and status of the dipper 140 and/or othercomponents of the shovel 100. For example, the controller 300 can becoupled to crowd sensors, swing sensors, hoist sensors, and shovelsensors. The sensors 380 may also include weight sensors, accelerationsensors, inclination sensors, loadpin strain gauges, gantry pins, motorfield modules, etc. to provide additional information to the controller300 relating to one or more operating conditions and/or characteristicsof the shovel 100 and/or of the dipper 140.

The crowd sensors indicate the level of extension or retraction of thedipper 140. The swing sensors indicate the swing angle of the handle135. The hoist sensors indicate the height of the dipper 140 based onposition of the hoist cable 155. The shovel sensors indicate whether thedipper door 145 is open (for dumping) or closed and may also includeweight sensors, acceleration sensors, and inclination sensors to provideadditional information to the controller 300 about the load within thedipper 140.

In some embodiments, one or more of the crowd sensors, swing sensors,and hoist sensors are resolvers that indicate an absolute position orrelative movement of the motors used to move the dipper 140 (e.g., acrowd motor, a swing motor, and/or a hoist motor). For example, forindicating relative movement, as the hoist motor rotates to wind thehoist cable 155 to raise the dipper 140, the hoist sensors output adigital signal indicating an amount of rotation of the hoist and adirection of movement. The controller 300 translates the sensor outputsto a height/position, speed, and/or acceleration of the dipper 140.

A hoist drive module, a crowd drive module, and a swing drive module areconfigured to receive control signals from, for example, the controller300 to control hoisting, crowding, and swinging operations of the shovel100. The control signals are associated with drive signals for hoist,crowd, and swing motors of the shovel 100. As the drive signals areapplied to the motors, the outputs (e.g., electrical and mechanicaloutputs) of the motors are monitored and fed back to the controller 300(e.g., via field modules). The outputs of the motors include, forexample, motor speed, motor torque, motor power, motor current, etc.Based on these and other signals associated with the shovel 100 (e.g.,signals from the inclinometer), the controller 300 is configured todetermine or calculate one or more operational states or positions ofthe shovel 100 or its components. In some embodiments, the controller300 determines a dipper position, a dipper handle angle or position, ahoist wrap angle, a hoist motor rotations per minute (“RPM”), a crowdmotor RPM, a dipper speed, a dipper acceleration, etc.

As noted above, the controller 300 is configured to retrieve from themedia 355 and execute instructions related to control processes andmethods for the shovel 100. For example, FIG. 3 illustrates a controlmethod 400 performed by the controller 300 based on instructionsexecuted by the processor 350 to provide additional crowd reach duringthe truck loading phase of the dig cycle. As noted above, the length ofthe handle 135 defines the reach of the dipper 140, and, in existingshovels, the entire length of the handle 135 can be used to perform eachphase of the dig cycle. However, for some phases, the optimal reach ofthe dipper 140 may vary based on the current phase of the dig cycle. Inparticular, additional dipper 140 reach may be advantageous during thetruck loading phase to ensure proper loading of the dump truck or mobilecrusher.

Therefore, as represented by the method 400 illustrated in FIG. 3, thecontroller 300 can provide or enable additional dipper reach during thetruck loading phase of the dig cycle. The method 400 uses feedback fromthe shovel sensors 380 (e.g., the swing and crowd sensors) to determinea current phase of the dig cycle and controls dipper reach accordingly.In particular, as the swing motor speed passes a baseline set-point(e.g., about 300 RPM), the controller 300 begins to monitor anddetermines when plugging (e.g., decelerating to stop swinging movementof the base 110) begins. Alternatively or in addition to using abaseline set-point for swing speed, the controller can monitor thecurrent shovel state to determine when the shovel 100 has transitionedto a “swing state”.

When the shovel 100 is plugging, the controller 300 can perform anoptional check of the dipper load (optional and alternative steps forthe method 400 are illustrated in FIG. 3 with a dashed line). The hoistload calculation is checked to determine if the dipper 140 is empty. Ifthe dipper 140 is empty, no extended crowd reach is needed as nomaterials are available for depositing during a truck loading phase.

If the dipper 140 is not empty (e.g., a dipper load equal to or greaterthan about 25% of maximum payload) and while the shovel is plugging, thecontroller 300 (e.g., continuously) monitors swing speed to determinewhen swing speed has slowed to a minimal level. The minimal levelindicates that the operator has reached the mobile crusher 175, the dumptruck 175A or other location for dumping material. At this point, thecontroller 300 enables the extended reach and limits hoist bail pull(e.g., to between 75% and 95% of standard hoist bail pull when in amotoring only condition (not generating torque)) in quadrant 1 (i.e.,positive torque and speed—see FIG. 4) to minimize overturning tippingmoment. The controller 300 then increases the existing boom limits toallow for extended reach of the crowd motion of the dipper 140. Thecontroller 300 can also display a message alerting the operator thatextended reach of crowd motion is currently enabled (e.g., via a messagein a GUI provided by the operator interface 370).

After the extended crowd reach is enabled, the controller 300 monitorscrowd position to determine when the operator has retracted the dipper140 back inside the standard boom limits profile. At this point, thecontroller 300 disables extended crowd reach and returns the shovel 100to standard production parameters. Alternatively or in addition todetermining when the operator has retracted inside standard boom limits,the controller 300 can monitor the shovel states and disable theextended reach and reset shovel parameters when the operator enters the“dig prep state” or “tuck state”.

In some embodiments, the controller 300 can also enable the extendedcrowd reach based on other sensors or control systems or methods. Forexample, in some arrangements, the controller 300 can sense the positionof the hopper 170 of the mobile crusher 175 or of the dump truck 175A(or receive positional information from a separate controller or sensor)and enable the extended crowd reach when the shovel 100 is positioned bythe mobile crusher/dump truck for loading and/or when extended crowdreach is useful for optimal load placement.

In some independent embodiments, the method 400 illustrated in FIG. 3can be used with a modified dipper handle 135′. FIGS. 5A-5B and 6A-6Cillustrate the handle 135′ for a shovel 100, 100A. The illustratedhandle 135′ can extend the reach of the dipper 140 approximately 18inches without an effective increase in the overall handle weight orlength.

Lengthened handles can interfere with the gantry platform on the cab 115(e.g., in some situations, there is only approximately 1 inch ofclearance between the end of the handle and the gantry hand rail on thecab 115 (see FIG. 6C)). To overcome these issues while still providingextended dipper reach, the handle 135′ includes an extended rack lengthwhile unused portions at the end of the handle 135′ are removed.

For example, as shown in FIG. 5A, as compared to an existing handledesign 500 (below in FIG. 5A), the handle 135′ (above in FIG. 5A) doesnot include the end part to the rear of the rack 165′ and greenhorn 170′as the existing handle 500 does (the end part 572 to the rear of therack 565 and the greenhorn 570). This end part 572 provides little or nofunctional support or guidance of the handle 500. The handle 135′ doesnot include this part and, thus, uses this removed structure to increasethe length of the rack 165′ relative to the length of the handle 135′.

As also illustrated in FIGS. 5A-5B and 6A-6C, the ends 174′ of thehandle 135′ are tapered (at 176′) to account for possible suspensionrope or hoist cable collisions. Previous handle designs (such as thehandle 500 shown in FIGS. 5A and 5C) are symmetrical top to bottomalthough collisions with suspension ropes primarily occur at the top ofthe handle. Therefore, to limit or minimize the impact of collisions,the handle 135′ includes an unsymmetrical chamfer 176′ on the handle end174′ in place of a symmetrical rounded end 572 of the existing handle500.

In addition, as noted above, the rack length of the handle 135′ isincreased approximately 18 inches. However, with the removal of thehandle end 572, the overall handle length is actually shortened byapproximately 7 inches. Therefore, the handle 135′ provides extendedreach of the dipper 140 with a shortened handle. In some arrangements,the handle 135′ thus allows for an approximately 8-inch clearancebetween the handle 135′ and the gantry guard rail (e.g., when the handletorsion box touches the boom 130 (see FIG. 6C)).

Also, in some embodiments, in addition to or as an alternative to usingthe handle 135′, the boom 130 can also be modified to allow the shippershaft to be moved rearward while continuing to provide truck loadingdipper range operators are accustomed to.

It should be understood that the modified handle 135′ is not required touse the control method described above (e.g., see FIG. 3 and method400). In particular, the control method can be used to limit and extendthe reach of the dipper 140 based on the current phase of the dig cycleregardless of the design or geometry of the handle or the shovel.

FIGS. 7A-7C and 8A-8C illustrate an alternative construction for amodified dipper handle 635 for a dipper 600. FIGS. 9A-9D provide moredetailed views of the handle 635. As shown in FIG. 9B, the handle 635includes spaced apart arms 642 connected by a mount 645 for the dipper140 (see FIGS. 7A and 8A). A rack 665 (see FIG. 9A) is formed on thebottom surface of each arm 642 and extends between end structure 670 (aremovable rear greenhorn 670 and a front rack termination 670). The rack665 is engageable with a drive pinion 672 (see FIG. 7C) driven by crowdmotor and transmission unit (not shown) to extend and retract the handle635 and attached dipper 640 (see FIG. 7A).

As shown in FIGS. 9C-9D, each arm 642 has a generally planar end surface680. Mounting positions 685 (see FIG. 9D), including an upper or firstmounting position 687, a lower or second mounting position 689 and anintermediate mounting position 691, are provided on each end surface680. The mounting positions 685 include fastener receiving openings 695defined in the end surface 680. The mounting positions 685 are describedbelow in more detail.

In FIG. 7A, the shovel 600 is illustrated during a digging phase withthe handle 635 fully crowded for digging. As discussed above, the shovel600 is controlled by controller 300 and method 400 to limit the reach ofthe handle 635 in certain operating phases of the shovel 600, such asthe digging phase (a “limited reach” phase). As shown in more detail inFIGS. 7B-7C, at least about 18 inches of the rack 665 (three teeth onthe rack 665 or about 19.5 inches in the illustrated construction)remains in this limited reach operating phase. In general, other thanthe loading phase (see FIGS. 8A-8B), the operating phases of the shovel600 are limited reach operating phases.

In FIG. 8A, the shovel 600 is illustrated during a loading phase withthe handle 635 fully extended for loading (with “extended reach”). Asdiscussed above, when the loading phase is determined, the controller300 enables extended reach of the handle 635 (the extended reach phase),and, as shown in FIG. 8B, the handle 635 may be fully extended to usethe full rack 665 substantially all the way to the greenhorn 670 (untilthe rear end of the handle 635 is approximately in line with the rearend of the wear plate 158). Further extension of the handle 635 islimited by the greenhorn 670 (see FIG. 8C) as a hard stop limit.

In the illustrated construction (see FIG. 9A), the modified handle 635(about 466.875 inches from the pin connection to the dipper 140 to theplane of the end surface 680) is slightly shorter than (see FIG. 5C) theexisting handle 500 (about 473.875 inches). However, the usable racklength of the handle 635 (about 323.68 inches) is longer than the usablerack length of the handle 500 (about 301.50 inches). Also, the rear endof the rack 665 of the handle 635 is closer to the end surface 680(about 22.56 inches) than the rear end of the rack 535 of the handle 500(about 49 inches). Finally, the rear greenhorn 670 is positioned at therear end of the handle 635 (only about 0.5625 inches from the plane ofthe end surface 680) while the rear greenhorn 570 of the handle 500 isfarther from the end (about 27 inches) (each rear greenhorn 670, 570 hasa length of about 22 inches).

In other constructions (not shown), the modified handle 635 and/or rack665 may have a different construction/relative location which is stillimproved over the existing handle 500 and/or rack 565. For example, insome constructions, the length of the rack 665 may be at least 65% ofthe length of the handle 635.

As another example, in some constructions, the distance between the rearend of the usable rack length and the end surface 680 may be less than10% or less than 5% of the length of the handle 635. Also, in someconstructions, the distance between the rear end of the usable racklength may be less than 15% or less than 10% of the length of the rack665. In some constructions, the distance between the rear end of therear greenhorn 670 and the end surface 680 may be less than orsignificantly less than the length of the greenhorn 670.

In some independent aspects, the shovel 100 may also include (see FIGS.10-14) a bracket assembly 710 for use with the handle 635. The bracketassembly 710 includes one or more brackets 715, each connectable to ahandle arm 642 in one or more orientations.

As shown in FIGS. 10A-10D, each bracket 715 generally includes a body720 having opposite surfaces 725, 730. One surface 725 is engageableagainst the end surface 680 of a handle arm 642, and a lifting opening735 is provided on the surface 730.

The body 720 also has opposite ends 740, 745. A guide 750, provided atone end 740, is operable, when installed, to guide the dipper handle 635during installation with the boom 630 (see, e.g., FIGS. 12A-12H and13A-13D). The guide 750 is provided by a non-planar portion 755 angledrelative to the generally planar remainder of the body 720. A guidesurface 760 is provided along the edge of the guide 750. Another liftingopening 765 is provided at the opposite end 745. Each bracket 715 may beformed of a single piece body 720 bent to provide the portion 755 andwith the structure of the lifting opening 735 fixed to the surface 730(e.g., by welding).

Fastener-receiving openings 770 (see FIGS. 10A and 10C) are provided inthe body 720. The openings 770 are located to correspond to positions ofthe openings 695 of the mounting positions 685. Fasteners 775 extendthrough the openings 770, 695 to connect the bracket 715 to the handlearm 642 in a desired mounting position 685 and orientation.

FIGS. 11-14 illustrate installation and use of the bracket(s) 715 withthe dipper handle 635 and installation of the dipper handle 635 to theshovel 600. In FIG. 11A, the handle 635 is positioned on its side in atransport position (e.g., for transport on a rail car). A bracket 715 isconnected to the upper dipper arm 642 in the first mounting position 687and in a transport removal orientation. In this orientation, the bracket715 extends transverse to the arm 642 with the second end 745 andlifting opening 765 projecting above the side of the arm 642. A clevis800 is shown connected to the lifting opening 765 and is connected to acrane (not shown) to lift the handle 635 from the transport. With thebracket 715 in the illustrated mounting position 687 and orientation,the handle 635 is rotated to a horizontal position (see FIG. 11B).

In some situations (see FIGS. 12A-12H), the handle 635 is installed in a“standing” position in which the dipper 640 is positioned on the groundwith the handle 635 extending upwardly. In FIG. 11C, each bracket 715 isconnected to an arm 642 in the first mounting position 687 and in apivoted second orientation (a “standing” position of the brackets 715).In this position/orientation, each bracket 715 is generally aligned withthe arm 642, and the second end 745 and the lifting opening 765 projectabove the top of the arm 642. The handle 635 is lifted from the positionshown in FIG. 11C to the position shown in FIGS. 11D and 12A-12H.

When the handle 635 is installed in the standing position, each bracket715 is connected to an arm 642 in the second mounting position 689 andin the illustrated orientation (see FIG. 11D; the “standing assembly”position). In this position/orientation, each bracket 715 is generallyaligned with the arm 642, and the second end 745 and the lifting opening765 project below the bottom of the arm 642.

Installation of the handle 635 in the standing position is illustratedin FIGS. 12A-12H. With the handle 635 in position, the shovel 600 ismoved forwardly to position the boom 630 between the arms 642. As theshovel 600 moves the boom 630 into position, the guide 760 on eachbracket 715 is engageable with the boom 630 to guide the boom 630/handle635 into proper position until the rack 665 engages the drive pinion672. The saddle block 657 is installed after the handle 635 ispositioned on the boom 630 (see FIGS. 12G-12H).

In other situations (see FIGS. 13A-13D), the handle 635 is lifted intoposition for installation. As shown in FIGS. 13A-13D, each bracket 715is connected to an arm 642 in the first mounting position 687 and in apivoted third orientation (a “lifted handle” position of the brackets715). In this position/orientation, each bracket 715 is generallyaligned with the arm 642, and the first end 740 and the guide 750project above the top of the arm 642. As shown in FIG. 13D, a clevis 800is connected to each lifting opening 735, and the handle 635 is liftedinto position on the boom 630.

After the handle 635 is installed, the brackets 715 may be removed fromthe arms 642 or may be stored on the arms 642 (see FIGS. 14A-14B). Asshown in FIGS. 14A-14B, each bracket 715 is connected to an arm 642 inthe intermediate mounting position 691 and in a storage orientation (a“storage” position of the brackets 715). In this position/orientation,each bracket 715 is generally aligned with the arm 642 and issubstantially within the periphery defined by the handle surfaces (sidesand top and bottom). In the illustrated construction, the intermediatemounting position 691 is provided by openings 695 from each of the othermounting positions 687, 689.

Compared to the existing handle 500 (see FIG. 5A) and the handle 135′(see FIGS. 5A-5B and 6A-6C) with fixed lifting members 178′, 578,respectively, the brackets 715 may provide flexibility for variouslifting operations for the handle 635. Further, in the storage position,the brackets 715 may minimize the rearward extent of the handle 635.

Thus, the invention may generally provide, among other things, anindustrial machine and a method of controlling an industrial machine toallow for optimal dipper extension during the digging phase whileextending available dipper reach during the loading phase. The inventionmay also provide a modified handle to provide extended reach withoutextending the length of the handle. In addition, the invention mayprovide a bracket assembly for use in positioning and installing thedipper handle on the shovel.

One or more independent features and/or independent advantages of theinvention may be set forth in the following claims:

What is claimed is:
 1. An assembly for a shovel, the assembly comprising: a dipper handle including a first end operable to support a dipper, the dipper handle having an end surface opposite the first end, the end surface including a first mounting feature and a second mounting feature; and a bracket having a first surface engageable against the end surface and a second surface opposite the first surface, the bracket including a first lifting opening, a first end, and a second end, the first lifting opening being coupled to the second surface, the first end defining a guide surface, the second end including a second lifting opening, the bracket being selectively connected to one of the first mounting feature and the second mounting feature, the bracket being selectively positioned in a first orientation relative to the dipper handle and a second orientation relative to the dipper handle.
 2. The assembly of claim 1, wherein each mounting feature includes a plurality of fastener-receiving openings, and wherein the assembly further comprises a plurality of fasteners, each of the plurality of fasteners being received in an associated opening to connect the bracket to the dipper handle in one of the first orientation and the second orientation.
 3. The assembly of claim 1, wherein the bracket is selectively connectable to the first mounting feature in one of the first orientation and the second orientation.
 4. The assembly of claim 1, wherein the first mounting feature and the second mounting feature cooperate to define an intermediate mounting feature, the bracket being connectable to the intermediate mounting feature in a third orientation.
 5. The assembly of claim 4, wherein the end surface of the dipper handle defines a periphery, wherein, in at least one of the first orientation and the second orientation, a portion of the bracket extends beyond the periphery defined by the end surface, and wherein, in the third orientation, the bracket is within the periphery defined by the end surface.
 6. The assembly of claim 1, wherein the dipper handle includes a pair of spaced apart arms, each arm having an end surface defining a first mounting feature and a second mounting feature, wherein the bracket is a first bracket selectively connectable to the end surface of one of the arms, and wherein the assembly further comprises a second bracket having a first surface engageable against the end surface of the other arm and a second surface opposite the first surface, the second bracket including a first lifting opening, a first end, and a second end, the first lifting opening provided on the second surface, the first end defining a guide surface, the second end defining a second lifting opening, the second bracket selectively connected to one of the first mounting feature and the second mounting feature of the other arm, the second bracket selectively positioned in a first orientation relative to the other arm and a second orientation relative to the other arm.
 7. The assembly of claim 1, wherein the guide surface is configured to engage a surface of a boom to guide the dipper handle relative to the boom during assembly of the dipper handle to the boom.
 8. A method for installing a dipper handle on a boom of a shovel, the dipper handle including a pair of parallel arms, each arm having a first end and a second end, each second end including an end surface having a periphery, the method comprising: coupling a bracket to an end surface of each arm in a mounting position, each bracket including a lifting opening and a guide surface positioned in an orientation relative to the dipper handle; while partially supporting the dipper handle by the lifting opening of each bracket, moving the dipper handle into an installation position; and moving one of the dipper handle and the boom in order to couple the dipper handle to the boom, as the dipper handle and the boom move toward one another, the guide surface of the bracket engaging the boom to align the dipper handle relative to the boom.
 9. The method of claim 8, further comprising: uncoupling the bracket from the end surface; and re-coupling the bracket to the end surface in a second mounting position with the lifting opening and the guide surface positioned in a second orientation relative to the dipper handle.
 10. The method of claim 9, wherein re-coupling the bracket to the end surface includes positioning the bracket with the lifting opening and the guide surface positioned within the periphery of the end surface.
 11. The method of claim 8, wherein moving the dipper handle into an installation position includes positioning the dipper handle with the first ends of the arms engaging a support surface and the second ends of the arms positioned substantially vertically above the first ends.
 12. The method of claim 8, wherein the dipper handle includes a rack on a lower portion of each arm, and wherein moving one of the dipper handle and the boom includes moving the boom between the second ends of the arms until the rack engages a drive pinion supported on the boom.
 13. The method of claim 12, wherein coupling the bracket in the first mounting position includes positioning each bracket with the guide surface extending beyond the periphery of the respective end surface proximate the lower portion of the respective arm.
 14. The method of claim 8, wherein moving one of the dipper handle and the boom includes partially supporting the dipper handle by the lifting opening of each bracket, and lifting the dipper handle into a position in which the handle is supported on the boom.
 15. The method of claim 14, wherein coupling the bracket in the first mounting position includes positioning each bracket with the guide surface extending beyond the periphery of the respective end surface proximate an upper portion of the respective arm.
 16. A dipper handle for a shovel, the dipper handle being operable to support a dipper, the handle comprising: a first end having a pin connection operable to support the dipper; a second end opposite the first end and defining an end surface, a distance between the first end and the second end defining a handle length; and a rack extending partially between the first end and the second end, the rack including a termination end proximate the first end and a greenhorn defining an end point of a usable portion of the rack, the greenhorn being positioned proximate the second end, the usable portion of the rack having a length at least 65% of the handle length.
 17. The handle of claim 16, wherein a distance between the greenhorn and the end surface is less than 10% of the handle length.
 18. The handle of claim 17, wherein a distance between the greenhorn and the end surface is less than 5% of the handle length.
 19. The handle of claim 16, wherein a distance between the greenhorn and the end surface is less than 15% of the length of the usable portion of the rack.
 20. The handle of claim 19, wherein a distance between the greenhorn and the end surface is less than 10% of the length of the usable portion of the rack.
 21. The handle of claim 16, wherein the greenhorn defines a length, and wherein a distance between the greenhorn and the end surface is less than the length of the greenhorn. 